Huck HS24LH User manual

Form HK 1024
04-22-2004
INSTRUCTION MANUAL
HS24LH
HYDRAULIC INSTALLATION TOOL

2
HS24LH Tooling Alcoa Fastening Systems
EU Declaration of Conformity
Manufacturer:
Huck International, Inc., Installation Systems Division, 1 Corporate Drive, Kingston, NY,
12401, USA
Description of Machinery:
Model numbers HS24LH fastener installation tools
Relevant provisions complied with:
Council Directive related to Machinery, (89/392/EEC), (91/368/EEC), (93/44/EEC),
(93/68/EEC)
Council Directive related to EMC/EMI, (89/336/EEC)
European Representative:
Rob Pattenden, Huck International, Ltd. Unit C Stafford Park 7, Telford Shropshire TF3 3BQ,
England, United Kingdom
Authorized Signature/date:
I, the undersigned, do hereby declare that the equipment specified above conforms to the
above Directive(s) and Standard(s).
Signature: ___________________________________
Full Name: Henk Rosier
Position: Engineering Manager
Installation Systems Division
Place: Kingston, New York, USA
Date: August, 2001
Sound Levels
Model: HS24LH
The sound level of the tool cycling without fastener is
Sound Exposure Level (SEL) = 87.2 dB(A)
Background (SEL) = 81.8 dB(A)
Peak Value = 92.9 dB(C)
The noise of the fastener being installed in structure is
considered process noise, not tool noise. Process
noise varies greatly from application to application.
Sound measurements of simulated process noise are
available upon written request from Huck International
in Kingston, NY 12401, USA.
Vibration Levels
Model: HS24LH
For an eight hour work day, installing 1000 typical Huck
fasteners will result in an equivalent weighted RMS
vibration level (Aeq) of .83 m/s2.
To calculate the equivalent vibration level for other
quantities of fasteners in an eight hour period, use the
formula:
Equivalent Vibration Level, Aeq (m/s2) = (n/480) x .4
where n = number of fasteners in eight hours, and .4
(m/s2) = Aeq for 60 seconds.
Test data to support the above information is on file at
Huck International, Inc., Kingston, NY, USA. Vibration
measurements are frequency weighted in accordance
with ISO 8041 (1990).

3
HS24LH Tooling Alcoa Fastening Systems
SAFETY
This instruction manual must be read with particular
attention to the following safety guide lines, by any
person servicing or operating this tool.
1. Safety Glossary
WARNINGS - Must be understood
to avoid severe personal injury.
CAUTIONS - show conditions that will
damage equipment and or structure.
Notes - are reminders of required
procedures.
Bold, Italic type and underlining -
emphasizes a specific instruction.
2. Huck equipment must be maintained in a safe
working condition at all times and inspected on a
regular basis for damage or wear. Any repair
should be done by a qualified repairman trained
on Huck procedures.
3. Repairman and Operator must read manual prior
to using equipment and understand any Warning
and Caution stickers/labels supplied with
equipment before connecting equipment to any
primary power supply. As applicable, each of the
sections in this manual have specific safety and
other information.
4. See MSDS Specifications before servicing the
tool. MSDS Specifications are available from
you Huck representative or on-line at
www.huck.com. Click on Installation Systems
Division.
5. When repairing or operating Huck installation
equipment, always wear approved eye
protection. Where applicable, refer to ANSI
Z87.1 - 1989
6. Disconnect primary power source before doing
maintenance on Huck equipment.
7. If any equipment shows signs of damage, wear,
or leakage, do not connect it to the primary
power supply.
8. Make sure proper power source is used at all
times.
9. Never remove any safety guards or pintail
deflector.
10. Never install a fastener in free air. Personal
injury from fastener ejecting may occur.
11. When using an offset nose always clear spent
pintail out of nose assembly before installing the
next fastener.
12. If there is a pinch point between trigger and
work piece use remote trigger. (Remote
triggers are available for all tooling).
13. Do not abuse tool by dropping or using it as a
hammer. Never use hydraulic or air lines as a
handle. Reasonable care of installation tools by
operators is an important factor in maintaining
tool efficiency, eliminating downtime, and in
preventing an accident which may cause severe
personal injury.
14. Never place hands between nose assembly and
work piece.
15. Tools with ejector rods should never be cycled
with out nose assembly installed.
16. When two piece lock bolts are being used
always make sure the collar orientation is
correct. See fastener data sheet of correct
positioning.
!
Product complies with requirements
set forth by the relevant European
directives.
Read manual prior to using
equipment.
Eye protection required while
using this equipment.
Hearing protection required while
using this equipment.

4
HS24LH Tooling Alcoa Fastening Systems
EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
PREPARATION FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
ADJUSTMENT OF SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
REMOVING ANVIL & THIMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
ASSEMBLY DRAWINGS/PARTS LIST (FIG 1-8) . . . . . . . . . . . . . . . . . .9-16
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
KITS & ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17&18
LIMITED WARRANTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
HUCK FASTENERS WORLD-WIDE LOCATIONS . . . . . . . . . . . . . . . . . . .20
CONTENTS

2.57
65
4.28
109
4.65
118
5.13
130 AT RETURN POSITION
2.32
59
2.75
70
1.75
44
2.87
73
1.20
30
2.54
65
2.71
69
20.47
520
1.36
34 FULL STROKE
31.60
803
144.00
366
18.00
457
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HS24LH Tooling Alcoa Fastening Systems
SPECIFICATIONS (HS24LH)
• Stroke: 1.36 in
• Capacity: 22400 lbs @ 7000 psi • Weight: 20 lbs • Pull Pressure: 7000 psi • Return Pressure: 6000 psi
INCHES
MM

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HS24LH Tooling Alcoa Fastening Systems
PREPARATION FOR USE (FOR 5/8” - 16MM)
1. Set the Huck POWERIG PULL pressure to 7,000 psi.
and RETURN pressure to 6,000 psi.. (Refer to
POWERIG instruction manual for setting pressures.)
2. Connect the Controller/Manifold to the POWERIG
per Controller/Manifold instruction manual.
3. Connect the tool's electrical, air and hydraulic lines to
the Controller/Manifold.
4. Select any tool and fastener in the controller as the
HS24 will not appear in the controller’s menu.
5. Change the controller to the following baseline
settings and adjust as necessary.
Controller Swage Pressure: 6,800 psi.
Controller Snub Pressure: 2,000 psi.
6. Turn on the POWERIG and run the warm-up cycle on
the Controller one or two times to remove all air from
the tool and hoses.
7. The HS24LH tool comes with a 5/8” - 16mm anvil
and thimble installed on tool. (If these have been
removed from the tool re-install at this time)
8. Test the tool by installing a fastener in washers at the
proper grip. Adjust POWERIG and Controller
settings as necessary to obtain a properly swaged
fastener.
!
WARNING - Be sure to connect tool hoses to
hydraulic unit BEFORE connecting tool
electrical switch cord to unit. Hoses and
switch must be connected in this order and
disconnected in the reverse order to prevent
possible severe personal injury.
!
WARNING - Proper PULL and RETURN
pressures are important for proper function
of Installation Tools. Severe personal injury
or damage to equipment may occur without
correct pressures. Huck Pressure Gauge
P/N T-10280 (old style) or the new T124833
is now available for checking these
pressures using instructions furnished with
the gauge and in applicable POWERIG®
Hydraulic Unit instruction manuals. See
Specifications.
PRINCIPLE OF OPERATION
When the Trigger is depressed and held down,
the automatic installation cycle starts. The Air
Motor is activated and rotates the Thimble
(clockwise), engaging onto the exposed thread of
the bolt. When the Thimble has engaged a
predetermined length of the thread (detected by
the Limit Switch Rod), theAir Motor stops and the
Powerig is activated, supplying hydraulic fluid
(Pull Pressure) to the rear of the Tool Piston
which moves forward to begin the Collar swaging
process. The Swaging Anvil then moves down
over the Collar. When a predetermined hydraulic
pressure (Pull Pressure) is reached, hydraulic
fluid (Return Pressure) is directed to the front of
the Piston, moving it rearward. The Swaging
Anvil then disengages from the Collar. The Air
Motor is then activated and rotates the Thimble
(counter-clockwise) to disengage the Tool from
the bolt thread. The Air Motor then stops and the
system is ready to install the next fastener.

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HS24LH Tooling Alcoa Fastening Systems
ADJUSTMENT OF SWITCHES (FOR 5/8” & 16MM)
REMOVE PLUG FOR ACCESS
TO THIMBLE LOCKING PIN
LIMIT S ITCH 2 ADJUSTING SCRE
LIMIT S ITCH 2 LOCKING SCRE S
LIMIT S ITCH 1 ADJUSTING SCRE
LIMIT S ITCH 1 LOCKING SCRE S
Switches:
The HS24 tool uses two limit switches. Limit switch one
(LS-1) senses when the tool's actuator rod first touches
the fastener with approximately .275in/7mm of the
fastener engaged in the thimble. This will allow the tool to
start a "snub" cycle. Limit switch two (LS-2) senses that
there is enough of the fastener engaged by the thimble,
approximately .500in/12.7mm to completely swage the
collar.
Set Up:
To set limit switches, connect the tool to appropriate
manifold and controller. Turn on all power except for the
hydraulic powering. The "tool connected" light should be
the only light illuminated on the controller/manifold.
Setting Limit Switch One:
Screw a fastener approximately .300in/7.5mm into the
thimble. Loosen the two screws that lock limit switch one
(LS-1) in place. Slide the screws forward or rearward until
the Limit Switch One (LS-1) just illuminates. If necessary
or helpful, move the adjusting screw at the back of the
switch housing in or out until the to the appropriate setting
is obtained. Tighten the two screws that lock the limit
switch.
Setting Limit Switch Two:
Screw a fastener approximately .525in/13.3mm into the
thimble. Loosen the two screws that lock limit switch two
(LS-2) in place. Slide the screws forward or rearward until
the Limit Switch Two (LS-2) just illuminates. If necessary
or helpful, move the adjusting screw at the back of the
switch housing in or out until the to the appropriate setting
is obtained. Tighten the two screws that lock the limit
switch.
Fig. A

8
HS24LH Tooling Alcoa Fastening Systems
System Inspection
Operating efficiency of the tool is directly related to the
performance of the complete system, including the tool,
controller, and POWERIG Hydraulic Unit. Therefore, an
effective preventive maintenance program includes
scheduled inspections of the system to detect and correct
minor troubles.
• Inspect tool and nose components for external damage.
• Verify that hydraulic hose fittings and electrical
connections are secure.
• Inspect hydraulic hoses for damage and deterioration.
Do not use hoses to carry tool. Replace hoses if
damaged.
• Observe tool, controller, hoses and hydraulic unit during
operation to detect abnormal heating, leaks or vibration.
POWERIG Hydraulic Unit Maintenance
Refer to the applicable POWERIG instruction manual.
Tool Maintenance
Whenever disassembled, replace all seals, wipers and
back-up rings in tool and also at regular intervals
(depending on severity and length of use). Service Kits,
hoses and extra parts should be kept in stock. Inspect
cylinder bore, pistons and piston rods for scored surfaces
and excessive wear or damage. Replace as necessary.
Nose Components Maintenance
This Tool has a integral nose assembly, at regular
intervals, as experience shows, inspect thimble and anvil
for signs of wear. Replace as necessary.
Controller
The Controller is basically maintenance free. Periodically
check all fittings and electrical connections.
PREVENTIVE MAINTENANCE
Removing Anvil:
Extend the hydraulic piston/anvil approximately. 3/8".
Place wrench Huck P/N: 126645 on the piston flats and a
1-11/16" wrench on anvil. Holding the piston, turn anvil to
remove.
Removing Thimble:
Remove anvil as previously described. Remove the pipe
plug at the back of the switch housing (see figure A). Turn
the thimble until the threaded hole for the locking pin is
visible through the pipe plug hole. Insert a 3/32" hex key
into the threaded hole and remove the thimble locking
pin. Remove thimble.
Installing Thimble:
With anvil removed, thread thimble into piston until it
bottoms. Thread locking pin in until it bottoms, then back
off 1/4 turn. Slowly thread thimble out while
simultaneously threading the locking pin in and out until it
moves into slot in end of thimble and tighten the locking
pin. The thimble should not be threaded out more than
1/4 turn from its bottom position.
Installing Anvil:
With the piston extended 3/8”, place wrench (126645) on
piston flats, thread anvil into piston and tighten with a 1-
11/16” wrench. If necessary loctite #242 may be applied
to the anvil threads before installations.
ANVIL & THIMBLE REMOVAL/INSTALLATION

9
HS24LH Tooling Alcoa Fastening Systems
FIGURE 1.
HS24LH TOOL ASSEMBLY DRAWING

10
HS24LH Tooling Alcoa Fastening Systems
FIGURE 2.
126601 SWITCH ASSEMBLY DRAWING

11
HS24LH Tooling Alcoa Fastening Systems
FIGURE 3.
126570 CYLINDER ASSEMBLY DRAWING

12
HS24LH Tooling Alcoa Fastening Systems
FIGURE 4.
126571 PISTON ASSEMBLY DRAWING

13
HS24LH Tooling Alcoa Fastening Systems
FIGURE 5.
126572 END CAP ASSEMBLY DRAWING

14
HS24LH Tooling Alcoa Fastening Systems
FIGURE 6.
126602 HYDRAULIC ASSEMBLY DRAWING

15
HS24LH Tooling Alcoa Fastening Systems
FIGURE 7.
126603 HANDLE/WIRING ASSEMBLY DRAWING

16
HS24LH Tooling Alcoa Fastening Systems
FIGURE 8.
126604 DRIVE ASSEMBLY DRAWING

17
HS24LH Tooling Alcoa Fastening Systems
TROUBLESHOOTING
Always check the simplest possible cause of a
malfunction first. For example, a loose or disconnected
trigger line. Then proceed logically and eliminate each
possible cause until the defect is found. Where possible,
substitute known good parts for suspected defective
parts. Use the following steps as an aid in
troubleshooting.
1. Tool fails to operate when trigger is pressed.
a. Inoperative POWERIG® Hydraulic Unit. See
applicable instruction manual.
b. Loose electrical connections.
c. Damaged trigger assembly.
d. Loose or faulty hose coupling.
e. Controller not turned on.
2. Tool operates in reverse. (Hydraulic Piston)
a. Reversed hose connections between hydraulic
unit and tool.
3. Tool operates in reverse (Air Motor)
a. Reverse air lines at controller.
4. Tool leaks hydraulic fluid.
a. Defective tool O-rings or loose connections at tool.
5. Hydraulic couplers leak fluid.
a. Damaged or worn O-rings in Coupler Body
Coupler P/N 110440.
6. Tool operates erratically and fails to install fastener
properly.
a. Low or erratic hydraulic pressure - - air in system.
b. Damaged or worn Piston seal in tool.
c. Excessive wear on sliding surfaces of tool parts.
7. Collar of fastener not completely swaged.
a. Improper tool operation - - see No. 6.
b. Scored anvil.
c. Rig/controller settings not correct.
d. Trigger released early.
9. Tool "hangs up" on swaged collar of fastener.
a. Improper tool operation - - see No. 6.
b. RETURN pressure too low.
SERVICE AND TOOL KITS
Service Kit - HS24KIT
Piston Wrench - 126645
SERVICE NOTES:

18
HS24LH Tooling Alcoa Fastening Systems
SERVICE NOTES:

HS24LH Tooling Alcoa Fastening Systems
LIMITED WARRANTIES
Tooling Warranty: Huck warrants that tooling and other
items (excluding fasteners, and hereinafter referred as
"other items") manufactured by Huck shall be free from
defects in workmanship and materials for a period of
ninety (90) days from the date of original purchase.
Warranty on "non standard or custom manufactured
products": With regard to non-standard products or
custom manufactured products to customer's
specifications, Huck warrants for a period of ninety (90)
days from the date of purchase that such products shall
meet Buyer's specifications, be free of defects in
workmanship and materials. Such warranty shall not be
effective with respect to non-standard or custom products
manufactured using buyer-supplied molds, material,
tooling and fixtures that are not in good condition or repair
and suitable for their intended purpose.
THERE ARE NO WARRANTIES WHICH EXTEND
BEYOND THE DESCRIPTION ON THE FACE HEREOF.
HUCK MAKES NO OTHER WARRANTIES AND
EXPRESSLY DISCLAIMS ANY OTHER WARRANTIES,
INCLUDING IMPLIED WARRANTIES AS TO
MERCHANTABILITY OR AS TO THE FITNESS OF THE
TOOLING, OTHER ITEMS, NONSTANDARD OR
CUSTOM MANUFACTURED PRODUCTS FOR ANY
PARTICULAR PURPOSE AND HUCK SHALL NOT BE
LIABLE FOR ANY LOSS OR DAMAGE, DIRECTLY OR
INDIRECTLY, ARISING FROM THE USE OF SUCH
TOOLING, OTHER ITEMS, NONSTANDARD OR
CUSTOM MANUFACTURED PRODUCTS OR BREACH
OF WARRANTY OR FOR ANY CLAIM FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Huck's sole liability and Buyer's exclusive remedy for any
breach of warranty shall be limited, at Huck's option, to
replacement or repair, at FOB Huck's plant, of Huck
manufactured tooling, other items, nonstandard or custom
products found to be defective in specifications,
workmanship and materials not otherwise the direct or
indirect cause of Buyer supplied molds, material, tooling
or fixtures. Buyer shall give Huck written notice of claims
for defects within the ninety (90) day warranty period for
tooling, other items, nonstandard or custom products
described above and Huck shall inspect products for which
such claim is made.
Tooling, Part(s) and Other Items not manufactured by
Huck.
HUCK MAKES NO WARRANTY WITH RESPECT TO
THE TOOLING, PART(S) OR OTHER ITEMS
MANUFACTURED BY THIRD PARTIES. HUCK
EXPRESSLY DISCLAIMS ANY WARRANTY
EXPRESSED OR IMPLIED, AS TO THE CONDITION,
DESIGN, OPERATION, MERCHANTABILITY OR
FITNESS FOR USE OF ANY TOOL, PART(S), OR
OTHER ITEMS THEREOF NOT MANUFACTURED BY
HUCK. HUCK SHALL NOT BE LIABLE FOR ANY LOSS
OR DAMAGE, DIRECTLY OR INDIRECTLY, ARISING
FROM THE USE OF SUCH TOOLING, PART(S) OR
OTHER ITEMS OR BREACH OF WARRANTY OR FOR
ANY CLAIM FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGES.
The only warranties made with respect to such tool, part(s)
or other items thereof are those made by the manufacturer
thereof and Huck agrees to cooperate with Buyer in
enforcing such warranties when such action is necessary.
Huck shall not be liable for any loss or damage resulting
from delays or nonfulfillment of orders owing to strikes,
fires, accidents, transportation companies or for any
reason or reasons beyond the control of the Huck or its
suppliers.
Huck Installation Equipment
Huck International, Inc. reserves the right to make
changes in specifications and design and to discontinue
models without notice.
Huck Installation Equipment should be serviced by trained
service technicians only.
Always give the Serial Number of the equipment when
corresponding or ordering service parts.
Complete repair facilities are maintained by Huck
International, Inc. Please contact one of the offices listed
below.
Eastern
One Corporate Drive Kingston, New York 12401-0250
Telephone [phone] FAX [phone]
Canada
6150 Kennedy Road Unit 10, Mississauga, Ontario,
L5T2J4, Canada.
Telephone [phone] FAX [phone]
Outside USA and Canada
Contact your nearest Huck International Office, see back
cover.
In addition to the above repair facilities, there are
Authorized Tool Service Centers (ATSC's) located
throughout the United States. These service centers offer
repair services, spare parts, Service Parts Kits, Service
Tools Kits and Nose Assemblies. Please contact your
Huck Representative or the nearest Huck office listed on
the back cover for the ATSC in your area.

Americas
Alcoa Fastening Systems
Aerospace Products
Tucson Operations
3724 East Columbia
Tucson, AZ 85714
800-234-4825
520-747-9898
FAX: [phone]
Alcoa Fastening Systems
Aerospace Products
Carson Operations
PO Box 5268
900 Watson Center Rd.
Carson, CA 90749
800-421-1459
310-830-8200
FAX: [phone]
Alcoa Fastening Systems
Commercial Products
Waco Operations
PO Box 8117
8001 Imperial Drive
Waco, TX 76714-8117
800-388-4825
254-776-2000
FAX: [phone]
Alcoa Fastening Systems
Commercial Products
Kingston Operations
1 Corporate Drive
Kingston, NY 12401
800-431-3091
845-331-7300
FAX: [phone]
www.hucktools.com
Alcoa Fastening Systems
Commercial Products
Canada Operations
6150 Kennedy Road, Unit 10
Mississagua, Ontario L5T2J4
Canada
905-564-4825
FAX: [phone]
Alcoa Fastening Systems
Commercial Products
Latin America Operations
Avenida Parque Lira. 79-402
Tacubaya Mexico, D.F.
C.P. 11850
FAX: [phone]
TELEX: 1173530 LUKSME
Far East
Alcoa Fastening Systems
Commercial Products
Australia Operations
14 Viewtech Place
Rowville, Victoria
Australia 3178
03-764-5500
Toll Free: 008-335-030
FAX: [phone]
Europe
Alcoa Fastening Systems
Commercial Products
United Kingdom Operations
Unit C, Stafford Park 7
Telford, Shropshire
England TF3 3BQ
01952-290011
FAX: [phone]
Alcoa Fastening Systems
Aerospace Products
France Operations
Clos D’Asseville
BP4
95450 Us Par Vigny
France
33-1-30-27-9500
FAX: [phone]
For the Long Haul™
A Global Organization
Alcoa Fastening Systems (AFS) maintains company
offices throughout the United States and Canada,
with subsidiary offices in many other countries.
Authorized AFS distributors are also located in
many of the world’s
industrial and Aerspace centers, where they provide
a ready source of AFS fasteners, installation tools,
tool parts, and application assistance.
For The Long Haul, The Future of Fastening Technology,
The Future of Assembly Technology,The Future of Tooling
Technology, and Tools of Productivity are service marks of Huck
International. Huck provides technical assistance regarding the use
and application of Huck fasteners and tooling.
NOTICE:The information contained in this publication is only for
general guidance with regard to properties of the products shown
and/or the means for selecting such products, and is not intended
to create any warranty, express, implied, or statutory; all warranties
are contained only in Huck’s written quotations,
acknowledgements, and/or purchase orders. It is recommended
that the user secure specific, up-to-date data and information
regarding each application and/or use of such products.
HWB898 1003-5M
© 2003 Alcoa Fastening Systems
1 Corporate Drive, Kingston, NY 12401 • Tel: [phone] • Fax: [phone] • E-mail: hk[email protected] • www.alcoafasteningsystems.com
Alcoa Fastening Systems world-wide locations:
One Great ConnectionSM